Front Head Gasket and Components

SHAFT SEAL, FRONT HEAD GASKET, INLET REED & VALVE PLATE REPLACE

Removal
1. Remove clutch assembly.
2. Drain oil from compressor through manifold openings.

Fig. 8 Compressor support & clamp assembly:

3. Install tool T81P-19623-D or equivalent on compressor to retain cylinder assembly and rear head in position, Fig. 8. Then clamp tool in a vise.

Fig. 9 Compressor shaft key removal:

4. Remove key from compressor shaft with tool T81P-19623-NH or equivalent, Fig. 9.
5. Remove six through bolts from compressor, then remove front head. Valve plate assembly, inlet reed, shaft seal and cylinder gasket will come off with head.
6. Lift inlet reed valve from head assembly.

Fig. 10 Valve plate removal:

7. Remove front valve plate assembly and gasket from front head with tool T81P-19623-B or equivalent, Fig. 10.
8. Remove gasket from valve plate assembly, use caution not to damage valve plate surface.
9. Remove dowel pin(s) from front head.
10. Remove shaft seal assembly and belt seal from head.

Fig. 11 Shaft seal seat assembly removal:

11. Place head on a piece of clean corrugated cardboard and remove seal seat assembly using tool T81-19623-OH or equivalent, Fig. 11.
12. Clean front head, valve plate assembly and inlet reed with clean solvent.

Installation
1. Inspect inlet reed, valve plate assembly and front head for damage, and replace any damaged parts.
2. Install dowel pin(s) in cylinder assembly.
3. Lubricate inlet reed with a light coating of refrigerant oil. Then position inlet reed with cylinder assembly, aligning hole(s) in inlet reed with dowel pin(s).
4. Assemble valve plate assembly to cylinder assembly aligning dowel pin(s) with hole(s).

Fig. 12 Disassembled view of valve plate & front head:

5. Assemble a new cylinder gasket to head side of valve plate assembly, Fig. 12.

Fig. 13 Shaft seal seat assembly installation:

6. Lubricate shaft seal with clean refrigerant oil and install seat in front head with groove on seat sealing surface up, using tool T81P-19623-C or equivalent, Fig. 13.
7. Lubricate shaft seat with clean refrigerant oil and assemble seal to compressor with sealing surface toward end of shaft. Engage internal plate of seal with two flats notched into shaft. Avoid handling carbon sealing surface of seal assembly to prevent damaging surface.
8. Install new O-ring in front head.
9. Position front head to cylinder assembly aligning dowel pin(s) with hole(s). Install six through bolts and torque to 24-25 ft. lbs. If replacing bolts, new bolts should be torqued to 18-19 ft. lbs.
10. Install key in slot of compressor shaft and felt seal in shaft bore of head.
11. Install clutch assembly on compressor and refill compressor with oil.